Printed Nonwoven Web And Method Of Making

ABSTRACT

A web of material having a plurality of ink droplets disposed thereon is disclosed. The ink droplets may be configured in a variety of different fashions on the web of material.

FIELD OF THE INVENTION

This invention relates to disposable absorbent products, and morespecifically to disposable absorbent products having visible imagesvisible on a topsheet thereof.

BACKGROUND OF THE INVENTION

Disposable absorbent articles, such as disposable diapers, sanitarynapkins, pantiliners, interlabial devices, incontinent devices, trainingpants, tampons, and the like, are known in the art. Printing on or belowthe top surface of an absorbent article is known in the art. Printing tocreate a signal that masks stains, for example, is known. Onecurrently-marketed disposable absorbent article, ALWAYS® brand sanitarynapkins, there is printed on one layer underlying the topsheet a colorsignal that is visible through the topsheet. By printing on a layerbelow the topsheet, the color signal can be viewed through the topsheetto provide for a perception of depth within the absorbent article. Depthperception of a printed color signal appears to be particularlyeffective when utilized with a three-dimensional formed film topsheet,as used on the aforementioned ALWAYS® brand sanitary napkin.

It would be desirable to gain the demonstrated advantages of printing acolor signal on a layer below the topsheet of a disposable absorbentarticle in an alternative manner that either (1) does not require anunderlying layer, or (2) can permit elimination of a layer of material,or (3) utilizes less ink or other printed medium to achieve anacceptable level of visual perception by a user.

SUMMARY OF THE INVENTION

A nonwoven web having printed thereon a colorant and/or a compositionproviding a skin health benefit is disclosed. The nonwoven web can be athree-dimensional, fluid pervious, polymeric web. The nonwoven web cancomprise apertures. The apertures are defined in a first surface of thenonwoven web in a first plane of the nonwoven web, and extend insidewall portions to a second surface in a second plane of the nonwovenweb. A colorant or lotion composition can be deposited on at least aportion of the second surface of the nonwoven web.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a portion of a three-dimensional formedfilm suitable for use in the present invention.

FIG. 2 is a perspective view of a three-dimensional formed film suitablefor use in the present invention.

FIG. 3 is a perspective view of a three-dimensional formed film suitablefor use in the present invention.

FIG. 4 is an enlarged perspective view of a portion of thethree-dimensional formed film shown in FIG. 3.

FIG. 5 is a perspective view of a three-dimensional formed film of thepresent invention.

FIG. 6 is a perspective view of a disposable absorbent article of thepresent invention.

FIG. 7 is a schematic representation of a flexographic printing processof the present invention.

FIG. 8 is a detail of the printing process shown in FIG. 7.

FIG. 9 is a photomicrograph of a web of the present invention.

FIG. 10 is a photomicrograph of a web of the present invention.

FIG. 11 is a schematic cross section of a nonwoven web of the presentinvention.

DETAILED DESCRIPTION OF THE INVENTION

A web, and method and apparatus for making a web are disclosed. The webcan be beneficially utilized as a topsheet or other component in adisposable absorbent article. The web can be a nonwoven web or apolymeric film, as each are known in the art for use as topsheets indisposable absorbent articles. In one embodiment, the web can be anonwoven web that is locally deformed, such as by embossing, to haveout-of-plane, i.e., “Z-direction” three-dimensionality. “Z-direction” asused herein has its ordinary meaning as used in the art of nonwoven websand absorbent articles, and refers to the direction generally orthogonalto the X-Y plane of a generally planar, generally flat web. Anembossment or other perturbation made in a generally flat, planar,nonwoven web is considered to be extended in the Z-direction.Z-direction perturbations in a web can be macroscopic, i.e., visiblewith the unaided eye at a distance of about 12 inches, and as such caneffectively increase the bulk of the web. Bulk is a measure that is theinverse of density, i.e., volume per unit mass, and can be increased byincreasing the effective thickness of the web without increasing theweb's basis weight. The three dimensional protrusions formed by theperturbations can define apertures, and can be uniform in a Z-directiondimensions (i.e, “height”) such that the distal ends of the protrusionscan be considered to end in a common plane, or surface, as describedbelow with respect to formed films. The web can be a formed film, suchas a macroscopically-expanded, three-dimensional, fluid pervious,polymeric web. The description below is in the context of a formed filmembodiment, but it is to be understood that in principle, the web,apparatus, and methods disclosed can be adapted to a three-dimensionallyformed nonwoven web.

FIG. 1 is an enlarged, partially segmented perspective illustration of aprior art macroscopically-expanded, three-dimensional, fluid perviouspolymeric web 40 formed generally in accordance with U.S. Pat. No.4,342,314 issued to Radel et al. on Aug. 3, 1982. Webs of this type havebeen found to be highly suitable for use as a topsheet in absorbentarticles such as sanitary napkins, pantiliners, interlabial devices, andthe like. The fluid pervious web 40 exhibits a plurality of macroscopicsurface aberrations that can be apertures, such as primary apertures 41.Primary apertures 41 are formed by a multiplicity of interconnectingmembers, such as fiber like elements, e.g., 42, 43, 44, 45 and 46, thatare interconnected to one another to define a continuous first surface50 of the web 40. Each fiber like element has a base portion, e.g., baseportion 51, located in plane 52 of first surface 50. Each base portionhas a sidewall portion, e.g., sidewall portion 53, attached to eachlongitudinal edge thereof. The sidewall portions extend generally in thedirection of a discontinuous second surface 55 of web 40. Theintersecting sidewall portions are interconnected to one anotherintermediate the first and second surfaces of the web, and terminatesubstantially concurrently with one another in the plane 56 of thesecond surface 55. Planes 52 and 56 can be substantially parallel andseparated by a distance termed herein as thickness or caliper H. In someembodiments, the base portion 51 may have surface aberrations 58 inaccordance with U.S. Pat. No. 4,463,045 issued to Ahr et al. on Jul. 31,1984. As used herein, the term “macroscopically expanded” refers to thestructure of a web formed from a precursor web or film, e.g., a planarweb, that has been caused to conform to the surface of athree-dimensional forming structure so that both sides, or surfaces, ofthe precursor web are permanently altered due to at least partialconformance of the precursor web to the three-dimensional pattern of theforming structure. The three-dimensional structure results in a firstsurface (e.g., first surface 50) and a second surface (e.g., secondsurface 55) that are a predetermined distance apart, the predetermineddistance being at least twice, three times, five times, or ten times thethickness of the precursor web or film. Such macroscopically-expandedwebs are typically caused to conform to the surface of the formingstructure by embossing (i.e., when the forming structure exhibits apattern comprised primarily of male projections), by debossing (i.e.,when the forming structure exhibits a pattern comprised primarily offemale depressions, or apertures), or by a combination of both.

As used herein, the term “macroscopic” refers to structural features orelements that are readily visible and distinctly discernable to a humanhaving 20/20 vision when the perpendicular distance between the viewer'seye and the web is about 12 inches. Conversely, the term “microscopic”is utilized to refer to structural features or elements that are notreadily visible and distinctly discernable to a human having 20/20vision when the perpendicular distance between the viewer's eye and theplane of the web is about 12 inches. In general, as used herein, theprimary apertures of a web disclosed herein are macroscopic, and surfaceaberrations, such as hair-like fibrils as disclosed more fully below areconsidered microscopic.

The term “planar” as used herein to refers to the overall condition of aprecursor web or film when viewed by the naked eye on a macroscopicscale, prior to permanently deforming the web into a three-dimensionalformed film. In this context, extruded films prior to post-extrusionprocessing and films that do not exhibit significant degree of permanentmacroscopic three-dimensionality, e.g., deformation out of the plane ofthe film, would generally be described as planar.

As utilized herein, the term “polymeric web” refers to webs comprisedsubstantially completely of polymeric material, such as polymeric filmsand nonwovens. The term “polymeric film” refers film polymeric webs,including webs made of polyethylene or polypropylene, and commonly usedfor topsheets and backsheets of disposable absorbent articles. Polymericfilms can be made by means well known in the art, including extrusion,cast, blown, and laminate methods such as co-extrusion. The term“nonwoven” or “nonwoven web” refers to nonwoven polymeric webs made ofpolymeric fibers, such as polyethylene, propylene, PET, and combinationsand blends, including bicomponent fibers, split fibers, and staplefibers. Nonwoven webs can be made by means well known in the art,including meltblown, spunlace, carded, airlaid, spunbond, and the like.

As utilized herein, the term “interconnecting members” refers to some orall of the elements of a web, e.g., web 40 in FIG. 1, portions of whichserve to define the primary apertures by a continuous network. As can beappreciated from the description of FIG. 1 and the present inventionherein, the interconnecting members, e.g., fiber like elements 42, 43,44, 45, and 46, are structurally continuous, with contiguousinterconnecting elements blending into one another in mutually adjoiningtransition portions. Individual interconnecting members can be bestdescribed with reference to FIG. 1 as those portions of the web disposedbetween any two adjacent primary apertures, originating in the firstsurface and extending into the second surface. On the first surface ofthe web the interconnecting members collectively form a continuousnetwork, or pattern, the continuous network of interconnecting membersdefining the primary apertures, and on the second surface of the webinterconnecting sidewalls of the interconnecting members collectivelyform a discontinuous pattern of secondary apertures.

In a three-dimensional, macroscopically-expanded web, theinterconnecting members may be described as channel-like. Their twodimensional cross-section may also be described as “U-shaped”, as in theaforementioned Radel '314 patent, or “upwardly concave-shaped”, asdisclosed in U.S. Pat. No. 5,514,105, issued on May 7, 1996 to Goodman,Jr., et al. “Upwardly-concave-shaped” as used herein, and as representedin FIG. 1, describes the orientation of the channel-like shape of theinterconnecting members with relation to the surfaces of the web, with abase portion 51 generally in the first surface 50, and the legs, e.g.,sidewall portions 53, of the channel extending from the base portion 51in the direction of the second surface 55, with the channel openingbeing substantially in the second surface 55. In general, for a planecutting through the web, e.g., web 40, orthogonal to the plane, e.g.,plane 52, of the first surface 50 and intersecting any two adjacentprimary apertures, e.g., apertures 41, the resulting cross-section of aninterconnecting member disposed therein will exhibit a generallyupwardly concave shape that may be substantially U-shaped.

The term “continuous” when used herein to describe the first surface ofa macroscopically-expanded, three-dimensional formed film web, refers tothe uninterrupted character of the first surface generally in the planeof the first surface. Thus, any point on the first surface can bereached from any other point on the first surface without substantiallyleaving the first surface. Conversely, as utilized herein, the term“discontinuous” when used to describe the second surface of athree-dimensionally formed film web refers to the interrupted characterof the second surface generally in the plane of the second surface.Thus, any point on the second surface cannot necessarily be reached fromany other point on the second surface without substantially leaving thesecond surface in the plane of the second surface.

FIG. 2 shows an enlarged, partially segmented, perspective illustrationof a portion of another prior art polymeric microapertured web 110formed generally in accordance with U.S. Pat. No. 4,629,643, issued toCurro et al. The micro-apertured surface aberrations 120 can be formedby a hydroforming process in which a high-pressure liquid jet isutilized to force the web to conform to a three-dimensional supportmember. As shown, ruptures which coincide substantially with the maximumamplitude of each micro-apertured surface aberration 120 result in theformation of a volcano-shaped aperture 125 having relatively thin,irregularly shaped petals 126 about its periphery. The relatively thin,petal-shaped edges 128 of the aperture of such a web provide forincreased softness impression on the skin of a user when compared, forexample, to the web of Ahr '045. It is believed that this softnessimpression is due to the relative lack of resistance to compression andshear afforded by the surface aberrations having volcano-shapedapertures. For webs of the type depicted in FIG. 2 having bothmacro-apertures (as shown in the web of FIG. 1) and micro-aperturesextending from first surface 50, the caliper H is the dimension fromplane 56 of second surface 55 to a plane of a surface correspondinggenerally to the petal-shaped edges 128 of volcano-shaped apertures 125.

FIG. 3 is an enlarged, partially segmented perspective illustration of afluid pervious, macroscopically-expanded, three-dimensional polymericweb 80 as taught in U.S. application Ser. No. 10/324,366, filed Dec. 20,2002, and entitled Polymeric Web Exhibiting a Soft and Silky TactileImpression. The geometric configuration of the macroscopic surfaceaberrations, e.g., primary apertures 71, of the polymeric web can begenerally similar to that of the web 40 illustrated in FIG. 1. Primaryapertures 71 may be referred to as “apertures” or “macro-apertures”herein, and refer to openings in the web that permit fluid communicationbetween a first surface 90 of web 80 and a second surface 85 of web 80.The primary apertures 71 of the web shown in FIG. 3 are defined in theplane 102 of first surface 90 by a continuous network of interconnectingmembers, e.g., members 91, 92, 93, 94, and 95 interconnected to oneanother. The shape of primary apertures 71 as projected in the plane ofthe first surface 90 may be in the shape of polygons, e.g., squares,hexagons, etc., in an ordered or random pattern. In a preferredembodiment primary apertures 71 are in the shape of modified ovals, andin one embodiment primary apertures 71 are in the general shape of atear drop. Polymer web 80 exhibits a plurality of surface aberrations220 in the form of hair-like fibrils 225, described more fully below.For webs of the type depicted in FIG. 3 having both macro-apertures 71and hair-like fibrils 225 extending from first surface 90, the caliper His the dimension from plane 106 of second surface 85 to a plane of asurface corresponding generally to the distal ends 226 of hair-likefibrils 225.

In a three-dimensional, microapertured polymeric web 80, eachinterconnecting member comprises a base portion, e.g., base portion 81,located generally in plane 102, and each base portion has sidewallportions, e.g., sidewall portions 83 extending from each longitudinaledge thereof. Sidewall portions 83 extend generally in the direction ofthe second surface 85 of the web 80 and join to sidewalls of adjoininginterconnecting members intermediate the first and second surfaces, 90and 85, respectively, and terminate substantially concurrently with oneanother to define secondary apertures, e.g., secondary apertures 72 inthe plane 106 of second surface 85.

FIG. 4 is a further enlarged, partial view of the three-dimensionalpolymeric web 80 shown in FIG. 3. The three-dimensional polymeric web 80comprises a polymer film 120, i.e., the precursor film, which can be asingle layer of extruded polymer or a multilayer co-extruded or laminatefilm comprising two or more layers. As shown in FIG. 4, film 120 is atwo-layer laminate comprising a first layer 101 and a second layer 103.Laminate materials may be co-extruded, as is known in the art for makinglaminate films, including films comprising skin layers. While it ispresently preferred that, as shown in FIG. 4, the polymeric layers,e.g., layers 101 and 103, terminate substantially concurrently in theplane of the second surface 106 it is not presently believed to beessential that they do so. One or more layers may extend further towardthe second surface than the other(s).

FIG. 4 shows a plurality of surface aberrations 220 in the form ofhair-like fibrils 225. The hair-like fibrils are formed as protrudedextensions of the polymeric web 80, generally on the first surface 90thereof. The number, size, and distribution of hair-like fibrils 225 onpolymeric web 80 can be predetermined based on desired skin feel. Forapplications as a topsheet in disposable absorbent articles, it ispreferred that hair-like fibrils 225 protrude only from the base portion81 in first surface 90 of polymeric web 80, as shown in FIGS. 3 and 4.Therefore, when web 80 is used as a topsheet in a disposable absorbentarticle, the web can be oriented such that the hair-like fibrils 225 areskin contacting for superior softness impression, and yet, the hair-likefibrils 225 do not obstruct fluid flow through macro-apertures 71.Moreover, having hair-like fibrils 225 with closed distal portions 226results in reduced rewet, i.e., reduced amounts of fluid beingre-introduced to the surface of the topsheet after having been firstpassed through the topsheet to underlying absorbent layers.

FIG. 5 shows a web of the present invention, the web 140 being in thisembodiment in all respects like the web of FIG. 1 but having printed onthe second surface 155 thereof a colorant, the colorant in thisembodiment being present in the form of ink deposits 160. Ink deposits160 can be described as discrete, spaced apart deposits of ink. Colorantcan be any of colorants suitable for deposition onto a polymeric film,including water-based inks and dyes, solvent-based inks and dyes,UV-curable inks or dyes, paint, pigment, or liquid colorants such asfood coloring. Colorant can be produce a color contrasting with thecolor of the web 140 and can be primary colors and common colors such asred, green, blue, yellow, pink, purple, orange, or black. If web 140 isdark colored, colorant can be light colors such as light gray, silver,white, or beige. The fluid pervious web 140 exhibits a plurality ofmacroscopic surface aberrations that can be apertures, such as primaryapertures 141. Primary apertures 141 are formed by a multiplicity ofinterconnecting members, such as fiber like elements, e.g., 142, 143,144, 145 and 146, that are interconnected to one another to define acontinuous first surface 150 of the web 140. Each fiber like element hasa base portion, e.g., base portion 151, located in plane 152 of firstsurface 150. Each base portion has a sidewall portion, e.g., sidewallportion 153, attached to each longitudinal edge thereof. The sidewallportions extend generally in the direction of a discontinuous secondsurface 155 of web 140. The intersecting sidewall portions areinterconnected to one another intermediate the first and second surfacesof the web, and terminate substantially concurrently with one another inthe plane 156 of the second surface 155. Planes 152 and 156 can besubstantially parallel and separated by a distance termed herein asthickness or caliper H. In general, caliper H of webs of the presentinvention useful as topsheets on disposable absorbent articles can be inthe range of 0.1 to 2 millimeters, and can range in 0.01 mm incrementsbetween these values. Caliper H can be from 0.40 to 0.60 millimeters.Caliper H can average about 0.44 millimeters. In some embodiments, thebase portion 151 may have surface aberrations 158 in accordance withU.S. Pat. No. 4,463,045 issued to Ahr et al. on Jul. 31, 1984.

In some embodiments, sidewall portions 153 end substantially uniformlysuch that the second surface 155 coincides substantially completely withplane 156. However, in some embodiments, sidewall portions 153 can endin substantially non-uniformly, such as in a somewhat jagged patternwherein various portions have differing height H dimensions. In such anembodiment, plane 156 can be considered located at an average distance Hdetermined by second surface 155. In each embodiment, sidewall portionsare considered to extend to a second surface in a second plane of theweb.

Ink deposits 160 are shown in FIG. 5 as being predominantly at thedistal ends of sidewalls 153, i.e., substantially only on the secondsurface 155. Because sidewalls can be relatively thin, including beingthinned from the original thickness of the starting film web materialdue to the process of making, and because ink can be deposited indroplets having dimensions greater than the sidewall thickness, in someembodiments ink deposits can extend some distance on the sidewall 153away form the distal end, and yet still be considered substantially onlyon the second surface 155. Therefore, in one embodiment, colorants inthe form of ink deposits 160 on the second surface 155 can be on thefilm edge, or primarily on the film edge at the distal ends of sidewallportions 153. In other embodiments, in addition to being on the filmedge at the distal ends of sidewall portions 153, ink can be on otherparts of the sidewall portions 153, including on the inner or outersurfaces of sidewall portions 153.

One advantage to having colorant deposited on at least a portion of thesecond surface of a three-dimensional, formed film web, such as a webillustrated in FIG. 5, is the impression of depth that is created. Whenused as a topsheet on an absorbent article, a web having colorantdeposited at a plane below the top surface provides for a visualimpression of depth and richness that is pleasing to consumers. Inaddition, because the colorant is actually placed at a plane below thetop surface, the colorant is, in fact, as far away from the user's skinwhen the web is used as a topsheet on an absorbent article. This remoteplacement can be beneficial for certain colorants in which it isundesirable for the colorant to be on or near the top surface of thetopsheet.

One advantage to the web of the present invention, and the methods formaking as described below, is that colorant, or a combination ofcolorants can be applied to the web at differing areas of sidewallportions 153. For example, a colorant can be applied to be limited tobeing at substantially second surface 155. Or the colorant, or anothercolorant having a different color, can be applied midway between firstsurface 150 and second surface 153. If more than one color of colorantis used, multiple planes of color can be created to provide novel visualeffects to a user viewing the web from the first surface side. When usedas a topsheet in an absorbent article, various colorants, colors ofcolorants, and placement options can be combined to create novel visualshapes, depth effects, color combinations. By way of example, in oneembodiment, a first colorant can be applied to the second surface of acentral region of a topsheet for a sanitary napkin, and a secondcolorant having a different color can be applied to the second surfaceof a side or end region of the topsheet. In another embodiment, a firstcolorant can be applied to the second surface of a central region of atopsheet for a sanitary napkin in a swirl shape, and a second coloranthaving a different color can be applied to the mid-sidewall portions inthe same region of the topsheet, and in the same swirl pattern toprovide for an optical effect. Of course, any combination of colorant,color, deposition location, shape of deposition can be contemplated,each having its own novel visual effect.

Ink deposits 160 on the second surface 155 of web 140 can be applied bya printing process, such as gravure printing and flexographic printingas described below. Other printing processes as are known in the art canbe used, each with various advantages and disadvantages. The advantageof printing via a flexographic printing process is that the nip settingat the printing stage can be adjusted and set such that only the secondsurface 155 of web 140 contacts the inked roll in a highly controllablemanner. The result is that ink deposits 160 can be precisely controlledso as to be applied on a surface of web 140 spaced a predetermineddistance from first surface 150. As discussed above, when web 140 isused as a topsheet on a disposable absorbent article, ink deposits 160on the second surface 155 can render a perception of depth visible fromthe user-facing side of the disposable absorbent garment. By achieving aperception of depth in this manner, underlying layers such as secondarytopsheets having printed signals can be eliminated without loss of thecolor signal capability. Also, by printing only on the second surface155 of a formed film, the amount of ink utilized for a commerciallyviable visual signal can be significantly reduced, as compared toprinting a color signal on an underlying layer, such as a secondarytopsheet or core layer.

Ink deposits 160 can be closely spaced so as to form a substantiallycomplete coverage of second surface 155, or they can be spacedrelatively far apart. The ink deposits 160 can be limited tosubstantially only on the very ends of sidewall portions 153, or the inkdeposit 160 can extend a substantial distance up sidewall portion 153 inthe direction of first surface 150. In one embodiment ink deposits 160are colorfast so that they do not dissolve, degrade, or run wheninsulted with at least one of water, urine, or menses. In anotherembodiment, ink deposits 160 can be soluble in at least one of water,urine, or menses, such that upon liquid insult the imprinted colorchanges or disappears. Such color change can indicate wetness, volume offluid, position of fluid, and/or type of fluid.

In one embodiment, ink deposits 160 can be printed so as to make agraphic image visible from the body-facing side of a disposableabsorbent article. For example, as shown in FIG. 6, the image can besimilar to that taught in co-pending, co-owned U.S. patent applicationSer. No. 10/025,059, filed Dec. 19, 2001, entitled Absorbent Article, orco-pending, co-owned U.S. patent application Ser. No. 10/967,454, filedOct. 18, 2004, entitled Absorbent Article.

FIG. 6 provides a perspective view of the absorbent article 210. Theabsorbent article 210 herein has an upper surface 222, a lower surface(not seen), and a periphery 212 comprising a topsheet 225 having abottom surface (not shown) and a viewing surface 232 positioned oppositeto the bottom surface. The viewing surface 232 faces upwardly towardsthe upper surface 222 of the absorbent article 210. The absorbentarticle 210 further comprises a backsheet 223 having a garment facingsurface (not shown) and a user facing surface positioned oppositely tothe garment facing surface, the backsheet 223 being joined to thetopsheet 225, as is common and known in the art. The absorbent article210 also comprises an absorbent core 220 having a top surface 221 and abottom surface (not shown) that is positioned opposite to the topsurface 221. The absorbent core 220 is positioned between the topsheet225 and the backsheet 223, as is common and known in the art.

The ink deposits 160 can render visible from the viewing surface 232 agraphic, such as graphic 240 shown in FIG. 6. In the embodiment shown inFIG. 6 the absorbent article 210 has at least two portions, i.e., aportion comprising graphic 240 and a portion 250 which does not comprisea graphic 240. The graphic 240 and the non-graphic portion 250 can beviewable from the viewing surface 232 of the topsheet 225. The graphic240 can have at least two shades, a first shade 242 and a second shade244. In one embodiment, as is shown in FIG. 6, the first shade 242 canbe positioned substantially within the second shade 244. The secondshade 244 can be different, either in lightness, darkness, and/or color,from the first shade 242. The multi-shades can operate to create anadditional perception of depth within the absorbent article by a userlooking upon the viewing surface 22 of the topsheet 225.

While the graphic shown in FIG. 6 is similar to the graphic shown in theaforementioned U.S. patent application Ser. No. 10/025,059, in thepresent invention the shape, size, coloration, placement, and intensityof graphic 240 can be varied in ways limited only by the size of thesubstrate and the printing techniques employed. For example, by use ofletter press, lithographic, screen printing, flexographic or gravureprinting techniques, virtually any graphic in any color or colorcombination can be rendered on topsheet 225. Moreover, by adjustingprocessing variables such as the nip between rollers in a flexographicprocess, the amount of ink and the position of ink can be varied to givevarious impressions of color intensity, brightness/darkness, hue,saturation, and depth perception.

In one embodiment, graphic 240 or other printed image can be imparted toa web, such as topsheet 225 by means of a flexographic printing process,such as that shown schematically in FIG. 7. Flexographic printingprocess 300 can utilize any of known flexographic printing apparatus andequipment, including processing means known in the art. As shown, ink305 is supplied in a chamber 310 comprising a doctor blade as is knownin the art, and which is in operative relationship with an anilox roller320 to which ink from the chamber 310 is transferred in a uniform manneras the anilox roller 320 rotates in the direction indicated. Aniloxroller 320 is in operative relationship with a plate roller 330 suchthat at transfer nip 340 ink is transferred from the anilox roller 320to the plate roller 330. The plate roller 330 picks up ink from theanilox roller 320 in a pattern corresponding to the pattern desired tobe printed on a substrate 345. The substrate 345 on which the patternwill be printed, such as a web for a topsheet of a disposable absorbentarticle, such as the sanitary napkin of FIG. 6, is fed onto the centralimpression drum 340 (in any conventional manner, not shown), which isrotating in the direction shown in FIG. 7.

As substrate 345 enters the printing nip 335 formed by the operationalrelationship of the surfaces of the plate roller 330 and the centralimpression roller 340, the ink 305 on the surface of the plate roller330 makes contact with, and is transferred to, the substrate 345.Sometimes referred to as an ink impression, the ink transfer patterncorresponds to the graphic 240 that is then visible on printed web 350and will ultimately be visible from the viewing surface 232 of thetopsheet 225 of an absorbent article.

Alternatives to the described flexographic printing process can beimplemented. For example, a plurality of printing nips 335 can bearranged, each with its corresponding ink supply and anilox/platerollers such that multiple patterns and graphics in multiple colors andcolor intensities can be imparted to substrate 345. In one embodiment,two such printing nips 335 can be used, each nip delivering color in aregistered pattern to render a two-color graphic image to substrate 345,which image can then be registered so as to be appropriately disposed onthe viewing surface 232 of the topsheet 225 of an absorbent article. Insome embodiments, when multiple print operations are performed, it canbe necessary that the ink from one printing operation dry sufficientlybefore the next printing operation. Therefore, in one embodiment,between printing operations there can be operatively positioned dryingmeans, such as infra-red heating, UV light curing, forced air drying,and the like, as is known in the art.

There are many advantages to printing images on three-dimensional,formed film webs by means of the present invention. For example, asshown in FIG. 8, a web, such as web 40 shown in FIG. 1 can be printed ina flexographic printing process with the first surface 50 facing into oron the central impression drum 340 and second surface 55 facingoutwardly with respect to the central impression drum 340. The gap Gbetween plate roller 330 and the central impression roller 340 can beset such that ink transfers only to the second surface 55 of web 40that, in this embodiment, is the substrate 345 that gets printed to bethe printed web 350. Once printed, the printed web 350 is a web 140 ofthe present invention as depicted in FIG. 5. Ink has been transferredvia the flexographic process to be deposited only on the second surface155 and, depending on the gap G, on portions of side walls 153.

Gap G can be adjusted depending on the caliper H of thethree-dimensional, formed film webs substrate 345. In one embodiment,gap G can be substantially equal to caliper H such that only the veryends of sidewall portions 153 in second surface 155 have ink depositedthereon. In another embodiment, gap G can be less than caliper H suchthat sidewall portions 153 are compressed through printing nip 335,resulting in ink being deposited on a portion of the sidewalls 153. FIG.9 is a photomicrograph showing about a 3 mm long (horizontally in FIG.9) section of the second surface 155 of a web 140 of the presentinvention showing ink deposits 160 on the ends of sidewall portions 153at substantially the second surface 155. FIG. 9 shows the underside of aweb similar to that shown in FIG. 5, the “underside” being used todenote the side of the web opposite first surface 150, and including thesecond surface 155. In actual use the either side could be the“underside” so the term is used here simply to denote the side printed,which happens to be the underside as oriented in FIG. 5, for example. Asconfigured in FIG. 9, web 140 is folded so as to better show at the topof the FIG., the cone-like structure formed by the sidewall portions153. As shown, the ink 305 is printed in a pattern of closely spaceddots on the distal ends of the sidewall portions 153 by a flexographicprinting process as described above with respect to FIG. 7. For thethree-dimensional, formed film webs substrate 345 printed and depictedin FIG. 9 as web 140, the ink is a water based ink available asGCOFW7835747 RD 11 from Sun Chemical, applied to a three-dimensional,formed film made by Tredegar Film Products, Haung Pu plant in Guangzhou,GD, China, having a caliper H of 0.44 mm (when measured under load of14.7 g/sq cm), in a flexographic PROGLIDE® printing process, made byMark Andy/Comco, Inc. 910 Lila Ave., Milford, Ohio, in which gap G wasadjusted to be about 0.01″ (0.254 mm).

In another embodiment, gap G can be adjusted such that at printing nip335 three-dimensional, formed film webs substrate 345 is significantlycompressed such that ink is deposited on the virtually all surfaces ofprinted web 140 except the first surface, such as first surface 50 ofthe web shown in FIG. 1. FIG. 10 is a photomicrograph showing about a 3mm long (horizontally in FIG. 10) section of the second surface 155 of aweb of the present invention showing ink deposited on virtually theentire underside of web 140, the term “underside” being used to denotethe side of the web opposite first surface 150, and including the secondsurface 155. In actual use the either side could be the “underside” sothe term is used here simply to denote the side printed, which happensto be the underside as oriented in FIG. 5, for example. As configured inFIG. 10, web 140 is folded so as to better show at the top of the FIG.the cone-like structure formed by the sidewall portions 153. As shown inFIG. 10, the cone-like structures have been somewhat deformed bycompression in the printing process, and the ink 305 is printed in apattern of closely spaced dots over virtually the entire underside ofthe web by a flexographic printing process as described above withrespect to FIG. 7. For the three-dimensional, formed film webs substrate345 printed and depicted in FIG. 10, the ink is a solvent based inkavailable as CROFS7711705 DPO-149 made by Sun Chemical, applied to athree-dimensional, formed film made by Tredegar Film Products, Haung Puplant in Guangzhou, GD, China having a caliper H of 0.44 mm (whenmeasured under load of 14.7 g/sq cm) in a flexographic PROGLIDE®printing process made by Mark Andy/Comco, Inc. 910 Lila Ave., Milford,Ohio in which gap G was adjusted to be about 0.0″ (0.0 mm).

In one embodiment the web of the present invention can be described as athree-dimensional, fluid pervious, web comprising a pattern ofprotrusions. As shown in FIG. 11, the substrate 345 can comprise anonwoven web 350 made by known processes including meltblown, spunbond,carding, airlaid, and wetlaid (e.g., paper), and the fibers can besynthetic, bicomponent, cellulosic, nanofibers, microfibers, shapedfibers, surfactant treated fibers, and other fiber types as known in theart, and the web can have sufficient light transmittance such that aprinted signal on one side can be seen through the web to the otherside. Protrusions 360 can be produced by means known in the art,including hot-pin punching, hot-pin aperturing, embossing, hydroforming,and vacuum forming. Two protrusions 360 are shown in the partial crosssectional view of FIG. 11, one having a closed distal end and one havingan open, apertured distal end. Protrusions 360 can extend in sidewallportions to distal ends 362 that collectively define a discontinuoussecond surface 355 in a second plane 356 of the web. Colorant 370, suchas ink or dye, can be deposited on at least a portion of the distal ends362 of protrusions 360, i.e., on the second surface 355 of the web.Protrusions 360 can include or define apertures 365, the apertures beingdefined in a first surface 354 of said web in a first plane 352 of theweb, and extending in sidewall portions to apertures substantially inthe second plane thereof. The distance H, which can be considered as theeffective thickness of the three-dimensional web 350, between the firstplane 352 and the second plane 356 can be twice the average thickness ofthe base nonwoven web, or three times, or four times, or at least aboutfive times. A web of this type can be beneficially used in sanitarynapkins because a topsheet utilizing such a web does not require anunderlying layer to provide a color signal visible to a user from thetopsheet surface. Further, by printing on a nonwoven web utilized as atopsheet, the manufacturer can eliminate a layer of material such as asecondary topsheet if the secondary topsheet was otherwise utilized as aprinting surface on which to print a color signal visible to a user fromthe topsheet surface. Further, printing a color signal on the nonwovenweb utilized as a topsheet as described herein utilizes less ink orother printed medium to achieve an acceptable level of visual perceptionby a user. By printing ink, for example, only on the distal portions of,i.e., the tips, of the protrusions of the second surface, a relativelylesser amount of ink can suffice to provide a commercially-acceptablevisual signal to a user of a disposable absorbent product.

In one embodiment, therefore, the web of the present invention can bedescribed as a three-dimensional, fluid pervious, polymeric web, the webcomprising a pattern of interconnecting members, the interconnectingmembers defining apertures, the apertures being defined in a firstsurface of said web in a first plane of said web, and extending insidewall portions to a second surface in a second plane of the web, andwherein ink is deposited on at least a portion of the second surface ofthe web. A web of this type, sometimes referred to as amacroscopically-expanded formed film, has beneficial use in sanitarynapkins, because a topsheet utilizing such a web does not require anunderlying layer to provide a color signal visible to a user from thetopsheet surface. Further, by printing on a web utilized as a topsheet,the manufacturer can eliminate a layer of material such as a secondarytopsheet if the secondary topsheet was otherwise utilized as a printingsurface on which to print a color signal visible to a user from thetopsheet surface. Further, printing a color signal on the web utilizedas a topsheet as described herein utilizes less ink or other printedmedium to achieve an acceptable level of visual perception by a user. Byprinting ink, for example, only on the tips of themacroscopically-expanded cones of the second surface, a relativelylesser amount of ink can suffice to provide a commercially-acceptablevisual signal to a user of a disposable absorbent product.

In another embodiment, lotions, surfactants, creams, and othercompositions providing skin health benefits can be applied to the secondsurface of a web, wherein the description above applies, with, forexample, lotion substituted for a colorant such as ink or dye. In oneembodiment, for example, a clear or color-tinted lotion of petrolatumcan be applied by known processes, such as by sufficiently heating forapplication by flexo-graphic printing means. Once deposited on the web,the heated petrolatum composition can then be cooled to solidify inplace, such as on sidewall portions of the web. In this manner, lotionsand lotion compositions can be applied alone, or as the colorant, orwith a colorant, or in combination with multiple colorants in multiplelocations on the web of the present invention, to provide for skinhealth benefits. Lotions compositions, for example, can be applied tothe second surface of a web utilized as a topsheet, such that duringuse, due to body heat, wearing motion, or fluid migration, the lotioncomposition can come into contact with the wearer's skin.

In another embodiment, a nonwoven/formed film laminate can be printed.In one embodiment, a nonwoven web can be joined, such as by adhesive orby thermal bonding to a surface of a formed film, either before or afterforming into a three-dimensional, fluid pervious, polymeric web. In thismanner, a formed film having a soft, fibrous surface can be achieved.

In another embodiment, webs having tufts formed therein, includinglaminates of films and nonwovens, can be printed as disclosed herein. Inone embodiment, the tufts can be formed by needle punching, or by therotary methods known as SELF'ing, rotary knife aperturing, and the like,as disclosed in co-pending, commonly assigned U.S. Ser. No. 11/156,020,filed 17 Jun. 2005; Ser. No. 10/737,306, filed 16 Dec. 2003; Ser. No.10/737,430, filed 16 Dec. 2003. The method of the present invention canbe utilized to deposit a lotion, colorant, or other fluid material onthe tips of tufts. In one embodiment, the method of the presentinvention can be used to print inks or dyes only on the tips of tufts ofa tufted nonwoven or laminate web.

All documents cited in the Detailed Description of the Invention are, inrelevant part, incorporated herein by reference; the citation of anydocument is not to be construed as an admission that it is prior artwith respect to the present invention. To the extent that any meaning ordefinition of a term in this written document conflicts with any meaningor definition of the term in a document incorporated by reference, themeaning or definition assigned to the term in this written documentshall govern.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm”.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A disposable absorbent article, comprising: atopsheet comprising a web of material, the web of material comprisingprotrusions comprising sidewall portions including a sidewall thickness;a backsheet; an absorbent core disposed between the topsheet and thebacksheet; and a plurality of ink droplets disposed on the sidewallportions; wherein the ink droplets comprise a length, width, and/orthickness that is greater than the sidewall thickness.
 2. The disposableabsorbent article of claim 1, wherein the web of material comprises anonwoven.
 3. The disposable absorbent article of claim 1, wherein theweb of material comprises a film.
 4. The disposable absorbent article ofclaim 1, wherein the web of material comprises a laminate comprising afirst layer and a second layer, wherein the first layer is a film or anonwoven and the second layer is a film or a nonwoven.
 5. The disposableabsorbent article of claim 1, wherein the topsheet further comprises afirst surface and a second surface, wherein the protrusions comprise aninner surface and an outer surface, wherein the inner surface comprisesthe first surface and the outer surface comprises the second surface,and wherein at least a portion of the ink droplets are disposed on theouter surface of the sidewall and a portion of the ink droplets aredisposed on the inner surface of the sidewall.
 6. The disposableabsorbent article of claim 5, wherein at least a portion of the inkdroplets are disposed on the second surface.
 7. The disposable absorbentarticle of claim 1, wherein each of the protrusions further comprises adistal end, wherein at least one of the distal ends is closed and one ofthe distal ends is open and forms an aperture.
 8. The disposableabsorbent article of claim 1, wherein the protrusions compriseapertures.
 9. The disposable absorbent article of claim 8, wherein afirst portion of apertures are smaller than a second portion ofapertures.
 10. The disposable absorbent article of claim 9, wherein thesidewalls of the first portion of apertures are oriented in a positiveZ-direction away from the absorbent core and the sidewalls of the secondportion of apertures are oriented in a negative Z-direction toward theabsorbent core.
 11. The disposable absorbent article of claim 9, whereinthe apertures comprise a length along a long axis and a width along atransverse axis, the transverse axis being perpendicular to the longaxis, and wherein the ink droplets are smaller than the length and/orwidth of the aperture.
 12. The disposable absorbent article of claim 1,wherein some of the protrusions comprise apertures and some of theprotrusions comprise embossments.
 13. The disposable absorbent articleof claim 12, wherein a portion of the ink droplets are disposed on adistal end of the embossments and a portion of the ink droplets aredisposed on the sidewalls portions of the apertures.
 14. The disposableabsorbent article of claim 1, wherein the plurality of ink dropletscomprise a first portion and a second portion, the first portioncomprising a first color and the second portion comprising a secondcolor, wherein the first color is different than the second color. 15.The disposable absorbent article of claim 1, wherein the protrusionscomprise tufts.
 16. The disposable absorbent article of claim 15,wherein the ink droplets are disposed on a distal end of the tufts. 17.A disposable absorbent article, comprising: a topsheet comprising a webof material, the web of material comprising protrusions comprisingsidewall portions having an inner surface and outer surface; abacksheet; an absorbent core disposed between the topsheet and thebacksheet; an ink droplet disposed on the inner surface of at least somethe sidewall portions; and an ink droplet disposed on the outer surfaceof at least some of the sidewall portions.
 18. The disposable absorbentarticle of claim 17, wherein the web of material comprises a nonwoven.19. The disposable absorbent article of claim 17, wherein the web ofmaterial comprises a film.
 20. The disposable absorbent article of claim17, wherein the web of material comprises a laminate comprising a firstlayer and a second layer, wherein the first layer is a film or anonwoven and the second layer is a film or a nonwoven.
 21. Thedisposable absorbent article of claim 17, wherein each of theprotrusions further comprises a distal end, wherein at least one of thedistal ends is closed and one of the distal ends is open and forms anaperture.
 22. The disposable absorbent article of claim 17, wherein theprotrusions comprise apertures.
 23. The disposable absorbent article ofclaim 22, wherein each of a first portion of apertures have a lengthalong a first long axis and a width along a first transverse axisperpendicular to the first long axis, wherein a second portion ofapertures comprise a length along a second long axis and a width along asecond transverse axis, and wherein the length and/or width of the firstportion of apertures are smaller than the length and/or width of thesecond portion of apertures.
 24. The disposable absorbent article ofclaim 23, wherein the sidewalls of the first portion of apertures areoriented in a positive Z-direction away from the absorbent core and thesidewalls of the second portion of apertures are oriented in a negativeZ-direction toward the absorbent core.
 25. The disposable absorbentarticle of claim 23, wherein the ink droplets are smaller than thelength and/or width of the second portion of apertures.
 26. Thedisposable absorbent article of claim 17, wherein some of theprotrusions comprise apertures and some of the protrusions compriseembossments.
 27. The disposable absorbent article of claim 26, wherein aportion of the ink droplets are disposed on a distal end of theembossments and a portion of the ink droplets are disposed on thesidewalls portions of the apertures.
 28. The disposable absorbentarticle of claim 17, wherein the plurality of ink droplets comprise afirst portion and a second portion, the first portion comprising a firstcolor and the second portion comprising a second color, wherein thefirst color is different than the second color.
 29. The disposableabsorbent article of claim 17, wherein the protrusions comprise tufts.30. The disposable absorbent article of claim 29, wherein the inkdroplets are disposed on a distal end of the tufts.
 31. A disposableabsorbent article, comprising: a topsheet comprising a web of material,the web of material comprising a plurality of protrusions comprising afirst protrusion comprising an open distal portion and a secondprotrusion comprising a closed distal portion; a backsheet; an absorbentcore disposed between the topsheet and the backsheet; an ink dropletdisposed on the first protrusion; and an ink droplet disposed on thesecond protrusion.
 32. The disposable absorbent article of claim 31,wherein the web of material comprises a nonwoven.
 33. The disposableabsorbent article of claim 31, wherein the web of material comprises afilm.
 34. The disposable absorbent article of claim 31, wherein the webof material comprises a laminate comprising a first layer and a secondlayer, wherein the first layer is a film or a nonwoven and the secondlayer is a film or a nonwoven.
 35. The disposable absorbent article ofclaim 31, wherein each of the plurality of protrusions comprise an innersurface and an outer surface, wherein at least a portion of the inkdroplets are disposed on the outer surface of the sidewall and a portionof the ink droplets are disposed on the inner surface of the sidewall.36. The disposable absorbent article of claim 31, wherein the firstprotrusion extends in a positive Z-direction and the second protrusionextends in a negative Z-direction.
 37. The disposable absorbent articleof claim 31, wherein the first protrusion extends in a negativeZ-direction and the second protrusion extends in a positive Z-direction.38. The disposable absorbent article of claim 31, wherein the firstprotrusion and the second protrusion extend in a positive Z-direction.39. The disposable absorbent article of claim 31, wherein the firstprotrusion and the second protrusion extend in a negative Z-direction.40. The disposable absorbent article of claim 31, wherein the inkdroplets are smaller than the open distal portion.
 41. The disposableabsorbent article of claim 31, wherein some of the protrusions compriseapertures and some of the protrusions comprise embossments.
 42. Thedisposable absorbent article of claim 41, wherein a portion of the inkdroplets are disposed on a distal end of the embossments and a portionof the ink droplets are disposed on the sidewalls portions of theapertures.
 43. The disposable absorbent article of claim 31, wherein theplurality of ink droplets comprise a first portion and a second portion,the first portion comprising a first color and the second portioncomprising a second color, wherein the first color is different than thesecond color.
 44. The disposable absorbent article of claim 31, whereinthe second protrusion comprises a tuft.
 45. The disposable absorbentarticle of claim 44, wherein the ink droplets are disposed on the closeddistal end of the tuft.
 46. A disposable absorbent article, comprising:a topsheet comprising a web of material, the web of material comprisingapertures, each of the apertures comprising a length along a long axisand a width along a transverse axis perpendicular to the long axis; abacksheet; an absorbent core disposed between the topsheet and thebacksheet; and a plurality of ink droplets disposed on the web ofmaterial, at least some of the ink droplets being smaller than thelength and/or width of the apertures.
 47. The disposable absorbentarticle of claim 46, wherein the web of material comprises a nonwoven.48. The disposable absorbent article of claim 46, wherein the web ofmaterial comprises a film.
 49. The disposable absorbent article of claim46, wherein the web of material comprises a laminate comprising a firstlayer and a second layer, wherein the first layer is a film or anonwoven and the second layer is a film or a nonwoven.
 50. Thedisposable absorbent article of claim 46, wherein at least a portion ofthe plurality of ink droplets are disposed on an inner surface of theapertures.
 51. The disposable absorbent article of claim 46, furthercomprising a plurality of embossments.
 52. The disposable absorbentarticle of claim 51, wherein at least a portion of the plurality of inkdroplets are disposed on a distal end of the embossments.
 53. Thedisposable absorbent article of claim 46, wherein the plurality of inkdroplets comprise a first portion and a second portion, the firstportion comprising a first color and the second portion comprising asecond color, wherein the first color is different than the secondcolor.
 54. The disposable absorbent article of claim 46, furthercomprising a tuft.
 55. The disposable absorbent article of claim 54,wherein the ink droplets are disposed on a distal end of the tuft.
 56. Adisposable absorbent article, comprising: a topsheet comprising a web ofmaterial, the web of material comprising a plurality of apertures; abacksheet; an absorbent core disposed between the topsheet and thebacksheet; and a plurality of ink droplets comprising a first colordisposed on a first plane and a plurality of ink droplets comprising asecond color disposed on a second plane, wherein the first color and thesecond color are different.